Light-transmitting structural panel



July 31, 1962 M. GRAYBOFF LIGHT-TRANSMITTING STRUCTURAL PANEL Filed Jan.25, 1959 I NVEN TOR: MAQ/L y/y G94 )1GO/ff' B2 A A TZOQNEY United StatesPatent Oiiice Patented July 31 1962 3,045,617 LIGHT-TRANSMHTINGSTRUCTURAL PANEL Marilyn Grayboiii, S1 Perry Road, Bloomfield, NJ. FiledJan. Z3, 1959, Ser. No. 788,619 3 Claims. tCl. 20-15) This inventionrelates generally to light-transmitting structural panels, and hasparticular reference to panels of grid-like nature intended primarilyfor ceiling inst-allations, rigidifying cores for sandwich panelconstruction, and solar shade devices.

It is the general Vobject of the invention to provide a panel which hasstructural value in that it is stiffer and more rugged, per unit weight,and can span greater hori- Zontal distances without supplementarysupport than open work structures heretofore used.

A more particular `object of the invention is `to provide a panel thatmay be manufactured at relatively low cost from simple sheet stock, andthat may if desired be formed in its entirety of a single sheet ofappropriate flat material such as aluminum or `other metal, or plastic.

Another object of the invention is toI provide a bas-ic structuralpattern which lends itself readily to variations that produ-cecorrespondingly different effects in ithe appearance andlight-transmitting or light-baffling qualities of the resultant panel.

One of the advantages of the improved panel structure is .that it `maybe manufactured by existing machinery, and the manufacturing processinvolves no waste of material. Moreover, despite the fact that it can bemade of light-weight thin-gauge material, it is usually rigid andself-supporting, and can span large areas vwithout sagging or requiringextraneous reinforcement.

Another feature of the invention lies in the `special structural designwhich `makes both faces the same, and thus makes the panel reversible.This is of importance in installations involving odd-shaped areas, sinceleft-over or partially damaged sections o-f the panel are available foruse `either frontward or backward.

Another advantage achieved by the improved panel is that it is unusuallyornamental in appearance, yand by simple relatively minor modificationsin the basic design a large variety of different ornamental effects canbe obtained.

Several ways `of achieving these `objects and advantages, and such otherbenefits as may hereinafter be pointed out, are illustrated in theaccompanying drawings, in whichv'FIGURE l is a perspective Viewillustrating ya panel construction of the present invention in 'anintermediate stage of manufacture;

FIGURE 2 is a perspective View similar to FIGURE l, showing the panel inits fully manufactured condition;

FIGURE 3 is a partial sectional View taken substantially along the line3-3 of FIGURE l;

FIGURE 4 is a partial sectional view taken substantially along the line4-4 of FIGURE 2;

FIGURE 5 is a sectional view taken substantially along the line 5-5 ofFIGURE 4;

FIGURE 6 is a sectional view similar to FIGURE 4. illustrating amodified form of the invention;

FIGURE 7 is a sectional View generally similar to that of FIGURE 5,illustrating another modification;

FIGURE S is la sectional view similar to FIGURES 5 and 7, illustratingstill another embodiment of fthe invention; and

FIGURE 9 is a sectional view similar to FIGURE 8, showing a furthermodification of the invention.

In forming a panel of the improved kind, an initially Vflat sheet 10 isfirst bent or rolled into a generally corrugated crosssectionalconfiguration. TheV 'sheet` may be of metal, plastic, or other suitablybendable material, and may be quite thin. For example, aluminum :sheethaving a thickness of 0.014 inch has proven satisfactory for thepurpose.

The bending ofthe sheet is such as to form 'a plurality of `alternatefiat-faced ridges 11 and troughs 12. Thus, the uppermost region or crestof each ridge 11 is an elongated flat wall 13. These walls extend insubstantially coplanar relation to all the other similarly located walls13. Extending downwardly from the longitudinal sides of the walls 13 arespaced side walls 14. In the preferred construction illustrated thesewalls 14 are perpendicular `to the walls 13. At their lower edges thewalls 14 join the elongated fiat walls 15 which are, `like the walls 13,in coplanar relation to one another.

Since the ridges 'on each side of the panel define the troughs on theother, it will be understood that each of the hat faces 13 (shownuppermost in FIGURESl and 2) is just `as much the floor of a trough asany `of the flat faces 15, Similarly, with respect to each trough floor,the ladjacent pair of walls 14 defines the Iside walls of the trough.For the sake of convenience, therefore, the walls 13 and 15 may bereferred to herein in terms of ridges and troughs, as well as upper andlower.

In manufacture, the ridges and troughs may -be rolled or otherwiseformed in the sheet 10 by bending the sheet downwardly along the lines18 vand upwardly `along the lines 19. The corners 13 define thelongitudinal boundaries `of the top walls 13, `and the corners 19 definethe longitudinal boundaries of the bottom Walls r15.

The bends 18 and 19 are preferably arranged parallel to one another, andit is also advantageous to locate the bends 1S on opposite sides of eachtop wall 13 at the same distance from each other as the bends 19 onopposite sides of each bottom Wall 15. Moreover, it is preferable tomake all the side walls 14 of the same height. As a result, the top andbottom walls 13 and 15 will all be of the same lateral dimension, andthe corrugations of the sheet 10 will be of the same dimensions on bothsides of the sheet.

`Formed in each top wall 13, at longitudinally spacedintervals, are aplurality of generally U-shaped cuts or severance lines 20. The U-shapedcuts have bight o r end portions extending generally laterally orcrosswise, and legs extending generally longitudinally close to theopposite top wall corners 18. Extending crosswise between the free endsof each U-shaped cut 20 is a bend line 21. In this way a generallyrectangular 'area 22 is defined within each U-shaped cut 20 and bendline 21, andl these areas are arranged in a row along each top wall 13.These areas are spaced from each other by intermediate bridges 23. Itwill be noted that in FIGURE 1 the end portion of each cut 20 is nearerto the observer, while the bend 21 associated with the cut is remotefrom the observer. Y

Each wall 15 is also formed with a series or row of generally U-shapedcuts V25, spaced longitudinally; with each cnt having its end portionextending laterally or crosswise, and its legs extending longitudinallyadjacent to' the opposite corners 19 Yof each bottom wall.` Extend'- ingcrosswise between the free ends of each cut 25 is a bend line 26. Y Eachofthe cuts 25 and its associated bend 26 defines an'enclosed generallyrectangular Varea 27. There are a plurality of such areas 27 oneachbottom wall 15. These areas are in substantial alignmentVV with the topwall `areas 22, in the construction chosen for illustrationl inFIGURE 1. bridges 28 between ladjacent bottom Wall areas 27 are insubstantial lateral alignment with Vthe 'topf wallfbridg'e's 23.' Itwill also be noted that in FIGUREl `the end portions of the bottom wallcuts 25 are remote'r from th'e observer, while the bend lines 26 arenearerytofthe 0bserver.k V;

' The sheet 10 in the condition of FIGURE' l isalso illus- Similarly,the bottonr'wallv trated in FIGURE 3, wherein are seen the end portionsof the top wall cuts 20, and in hidden lines the end portions of thebottom Wall cuts 25. The bend lines 21 of the top walls, and 26 of thebottom walls, do not appear in FIGURE 3, as these lines are notnecessarily present at this stage of manufacture.

In FIGURES 2 and 4 the sheet 10 is shown at a later stage ofmanufacture, wherein the top wall areas 22 have been struck down intothe troughs beneath them, and the bottom wall areas have been struck upinto the troughs above them. Each struck-up portion or fin is preferablybent through an angle of from about to 90, and in the illustratedconstruction a 90 bend has been shown. Thus, each of the regions 22leaves at its former location in the top wall a through aperture oropening 29 bounded by the cut 20 and bend 21. Each region 22 constitutesa light barrier disposed crosswise within its trough between the sidewalls 14 of the trough.

As may be observed in FIGURE 5, the rectangular struck-down lightbarriers 22 have their lower ends lying adjacent to the plane of thebottom walls 15.

It will be observed that the light barriers and the trough side wallsconjointly define a mesh-like pattern of adjacent rows oflight-transmitting passages. Obviously these passages are well adaptedto pass a high percentage of light through the panel. In well-knownfashion, the surfaces of each passage effectively reiiect and diffusethe light that is passing through, and where the panel is employed as aceiling installation it serves in desirable fashion to obscure the lightsource from an observer at natural angles of observation.

It will also be observed that in the manufacture of the panel no wastematerial is involved. Moreover, the corrugating process, the formationof cuts, and the bending of the light barriers into their respectivetroughs are i procedures that may be carried out with existing machinesand by known techniques. Even though the sheet material of which thepanel is made may be relatively thin and light in weight, the resultantpanel structure is unusually staunch and form-retaining. This is due inpart to the vertically arranged walls 14 which have a substantialrigidifying effect.

Another advantage of the construction stems from the slight clearancebetween the bent fins and the Walls 14, since deformation is thusprevented. For example, if one part of the panel is deformed by a blow,the impact will not be readily transmitted to adjoining parts since theclearances at the edges of the bent light barriers have a cushioningeffect. This desirable quality is absent from grids of rigidly assembledor welded kind. Moreover, the clearances referred to allow for greatertolerance in fitting the panels since slight compression or stretchingof the panel is feasible. This adaptability is absent from rigidlyassembled or welded structures.

The panel may be employed in the form of sections having a shape andsize as may be best suited for any particular purpose. Generally thepanel sections are rectangular, approximately four feet square, and thewidth of each trough may be approximately an inch or so. Thesedimensions are given by way of illustration only, and it will be readilyunderstood that these dimensions may be varied without altering thebasic nature of the structure. The supporting of each panel in ahorizontal disposition (for a ceiling installation or the like) presentsno particular problems. Each section is readily adapted to be supportedalong any of its marginal edges.

While the construction shown in FIGURES 1-5 illustrates the openings 29and 30 as being relatively large, and the connecting bridges 23 and 28correspondingly narrow, the openings in the panel may, if desired,occupy a lesser proportion of the panel area. For example, in FIGURE 6there is shown an arrangement in which the 4laterally extending top wallbridges 23a (corresponding to the bridges 23 of FIGURES 1-5) occupy agreater proportion of the total top Wall area, `while the openings 29aoccupy a smaller proportion of the top wall area. The construction ofFIGURE 6 illustrates further that the struck-up light barriers 22a and27a need not necessarily be the same in depth as the troughs in whichthey lie. The panel of FIGURE 6 will transmit less light than that ofFIGURES l-5, but in some installations a modified construction of thiskind may be desirable or useful. Its ornamental effect, and its acousticqualities, are different from the constructions shown in FIGURES l-S.

FIGURE 6 illustrates also that it is possible to arrange the lightbarriers in offset planes, to produce correspondingly different lighttransmitting and light-Source concealing effects.

The modified construction shown in FIGURE 7 is one in which the top andbottom walls 13b an 15b have lateral `dimensions appreciably greaterthan the height of the trough side walls 14b. Depending upon thedimensions of the U-shaped cuts formed in the top and bottom walls, thetransverse light barriers may have a variety of dimensionalcharacteristics. As shown in FIG- URE 7, the depth or height of eachbarrier 22h and 27h is substantially the same as the total depth of thepanel, but this may obviously be varied to produce correspondinglydifferent ornamental effects, and corresponding variations in thelight-transmitting, light-source concealing and acoustical qualities ofthe panel.

Another possible modification is depicted in FIGURE 8, in which thestruck-down top wall light barrier areas 22C have a somewhat U-shapedconiiguration with a curved bight or free edge. Similarly, the struck-uplight barriers 27e have a free edge that is convexly rounded. In anarrangement of this kind, the openings that are left in the top andbottom walls will be correspondingly nonrectangular in shape. This maybe desirable under cern tain circumstances, for ornamental or otherreasons.

In the modified construction shown in FIGURE 9, each of the lightbarriers 22d and 27d is itself subdivided into a plurality of sections.These sections may be arranged 1`n a single plane, or otherwise, as maybe desired, and they may have the same or different heights.Correspondingly varied effects can thus be produced.

From the foregoing it will be noted that the invention provides alight-transmitting structural panel, and a method of manufacture, whichfully accomplish their intended objectives and are well adapted to meetpractical conditions of manufacture and use. By the employment of one ormore of the modifications suggested, the illuminating and acousticaleiects, as well as the esthetic appearance of the panel, may be variedto suit diverse conditions and tastes.

Although the panel structure with bends in the ius is primarily intendedfor horizontal disposition, as in ceiling installations, it will bereadily understood that vertical utilization for partition purposes,structural cores for stress-skin panels, or otherwise, is entirelyfeasible. Moreover, where the panels are to be installed vertically forsun shading or privacy, the fins can be bent to angles other than 90without affecting the strength or structural value of the panels.

In general it will be understood that many of the details hereindescribed and illustrated may be modilied by those skilled in the artwithout necessarily departing from the spirit and scope of the inventionas expressed in the appended claims.

I claim:

l. A light-transmitting structural panel comprising a single sheet bentalong parallel lines to provide a generally corrugated cross-sectionalcontour having alternate flat-faced ridges and troughs, the ridges oneach side of the panel defining the troughs on the other, the side wallsof each ridge and trough being parallel to each other and perpendicularto the face thereof, the trough bottoms being provided with `spacedstruck-up portions extending into said troughs, each of said portionslying across almost the entire width of said troughs to define lightbarriers, the ridge crests being provided with spaced struckdownportions extending into the interior of said ridges, each of saidportions lying across almost the entire width of said ridges to denelight barriers, said trough bottoms and ridge crests having openings inthe regions originally occupied by said struck-up and struck-downportions respectively, said openings occupying most of the area of saidridge crests and trough bottoms Iand said openings being separated byrelatively narrow connecting bridges joining the side walls of saidridges and troughs, and said barriers and the trough and ridge sidewalls conjointly defining a grid-like pattern of adjacent rows oflight-transmitting passages through the panel.

2. A panel according to claim 1, wherein there is clearance between thelateral edges of each struck-up and struck-down portion and therespective trough `and ridge side walls.

3. A panel according to claim 1, wherein said barriers and openings aresubstantially rectangular.

4. A/ panel according to claim 1, wherein the height of said barriers isapproximately equal to the depth of the troughs and height of the ridgesrespectively into which they extend.

5. A panel according to claim 1, wherein the height of said barriers isless than the depth of the troughs and height of the ridges respectivelyinto which they extend.

6. A panel according to claim 1, said barriers being substantiallyperpendicular to said trough bottoms and ridge crests respectively.

7. A panel according to claim 1, each of said barriers having a convexlyrounded free end.

8. A panel according to claim 1, each of said barriers comprising aplurality of closely adjacent sections arranged in a single plane andindependently anchored at their roots to the trough bottoms `and ridgecrests respectively.

References Cited in the tile Aof this patent UNITED STATES PATENTS ZaneDec. 24, 1940

